Vehicle tilt seat handle coupling

ABSTRACT

A coupling member for connecting a conventional handle to a lock release actuating shaft of an vehicle tilt seat mechanism. The coupling member comprises a relatively short shaft having contiguous first and second portions that are of different outer dimensions transverse to the length of the shaft. The larger one of the first and second portions has a recess extending a selected distance inwardly from a free outer end of such portion in a direction toward the smaller one of the two contiguous portions. Means are provided within the recess for detachably mounting and securely anchoring the coupling member on and to the lock release actuating the shaft for rotating same. The smaller one of the contiguous portions is adapted to project into a socket in the handle for the tilt mechanism, and has means thereon cooperating with means in the socket of the handle for preventing relative movement of the handle and coupling member when the handle is moved in a direction to rotate the lock release actuating shaft.

[0001] This application claims priority from U.S. ProvisionalApplication Serial No. 60/380,447 filed on May 14, 2001 which isincorporated by reference herein.

BACKGROUND OF THE INVENTION

[0002] 1. Technical Field

[0003] This invention relates generally to vehicle seats having a tiltback that is released from a locked position by a handle on the side ofthe seat and more particularly to an improved means of connecting thehandle to the tilt lock/release shaft of the tilt mechanism.

[0004] 2. Background Information

[0005] Seat recliner mechanisms frequently fail because the shaft thatprojects from the tilt mechanism and to which the handle is directlyattached breaks. The shaft is spring biased to a locking position andwithout the handle one cannot release the latch to change the tilt ofthe seat back. When such failure occurs the practice has been to replacethe entire recliner mechanism inside the seat as well as the handle thatattaches directly thereto. The repair is costly and requires about twohours of labor to install. Also the replacement used is a manufacturer'soriginal equipment part, or similar substitute therefor, and thus islikely to fail again for the same reason as the first i.e. a faultydesign.

SUMMARY OF INVENTION

[0006] An object of the present invention is to provide a quickinexpensive repair of an vehicle tilt seat mechanism wherein failure ofthe same has occurred due to a broken shaft that actuates the tiltlocking mechanism and onto which the handle can no longer be attached.

[0007] A further principal object of the present invention is to providean original equipment tilt seat mechanisms with a separate couplingmember inter-posed between and which connects the handle to the lockrelease shaft.

[0008] In keeping with the foregoing there is provided in accordancewith the present invention a coupling member for connecting aconventional handle to a lock release actuating shaft of an vehicle tiltseat mechanism. The coupling member comprising a relatively short shafthaving contiguous first and second portions that are of different outerdimensions transverse to the length of the shaft. The larger diameterportion defining a first portion and the smaller diameter portiondefining a second portion. The larger portion has a recess forming abore extending a selected distance inwardly from a free outer end in adirection toward the smaller portion. The recess includes means fordetachably mounting and securely anchoring the coupling member on aspindle or shaft, and mounting onto the lock release actuating shaft forrotating the same. The smaller portion is adapted to project into asocket in the handle for the tilt mechanism and has means thereoncooperating engaging means in the socket in the handle for preventingrelative movement of the handle and coupling member when the handle ismoved in a direction to rotate the lock release actuating shaft.

[0009] The present invention provides a means to repair handleassemblies, wherein the shaft has an outer free end portion broken offpreventing reconnecting the handle directly to the shaft. In accordancewith a further aspect of the present invention, there is provided amethod of reconnecting a handle to the lock release shaft of a seat backtilt mechanism on an vehicle seat. The method comprises providing acoupling member for cooperative engagement between a seat handle shaftand the handle. The coupling member includes a cylindrical couplingmember having a first end which includes a bore extending from thedistal end inwardly a selected distance and a second small end having anexternal diameter less than the first end. At least a portion of thesmaller second end projects into the recess provided in the handle. Theremaining portion of the lock release shaft projecting into the recessin the larger first end of the coupling securely anchoring the couplingmember to the handle and the shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A better understanding of the present invention will be had uponreference to the following description in conjunction with theaccompanying drawings in which like numerals refer to like partsthroughout the several views and wherein:

[0011]FIG. 1 is a side view of a portion of an vehicle seat having atilt back and a handle on the side of the seat for releasing the tiltlock mechanism;

[0012]FIG. 2 is an oblique view of the tilt mechanism to which thehandle attaches and in which an end portion of a lock release shaft hasbroken off thereby preventing connecting a handle directly;

[0013]FIG. 3 is a side view of a coupling member provided in accordancewith the present invention for attaching a conventional factoryreplacement handle to the broken shaft illustrate in FIG. 2;

[0014]FIG. 4 is a left side view of FIG. 3;

[0015]FIG. 5 is a bottom view of FIG. 3;

[0016]FIG. 6 is an exploded view of a handle, coupling member of thepresent invention and a tilt mechanism; and

[0017]FIG. 7 is an oblique view showing the parts of FIG. 6 in anassembled state in which the handle is attached to the mechanism of FIG.1 by a coupling member of the present invention shown in FIGS. 3 to 5.

[0018]FIG. 8a is a frontal view of an alternate embodiment of a integralone piece coupling member showing the use of internal keeper comprisingopposing splines in the larger rear portion of the coupling and an axialexterior groove extending along the surface of the front portionabutting the larger portion whereby a threaded set screw socket or boreis disposed in alignment with one of the splines and the groove anddisposed perpendicular thereto;

[0019]FIG. 8b is a isometric side view of the embodiment of the integralone piece coupling member shown in FIG. 8a, showing the bores formedwithin the smaller front portion with exterior axial grooves and largerrear portion together with a keeper comprising interior splines, andthreaded set screw socket shown in phantom lines in alignment with oneof the internal splines and external groove;

[0020]FIG. 8c is a perspective view of the integral one piece couplingmember shown in FIGS. 8a and 8 b showing the external groove within thesmaller front portion abutting the larger rear portion with internalsplines forming a keeper and a threaded set screw socket in alignmentwith the external groove;

[0021]FIG. 8d is a perspective view of a coupling member embodimentshowing the axial groove on the smaller portion without a keeper or thethreaded set screw socket in the rear portion;

[0022]FIG. 8e is a perspective view of a coupling member showing asmaller portion having an axial exterior groove aligned with a threadedset screw socket on the larger portion having a keeper consisting of aspline disposed in the larger portion opposite the threaded set screwsocket;

[0023]FIG. 8f is a perspective view of a coupling member showing asmaller portion having an axial exterior groove aligned opposite athreaded set screw socket on the larger portion and the keeperconsisting of a spline disposed in the larger portion intersecting thethreaded set screw socket;

[0024]FIG. 9a is a frontal view of an alternate embodiment of a integralone piece coupling member showing the use of a pair of offset externalaxial grooves in the smaller front portion abutting the larger portionwhereby a threaded set screw socket is disposed in offset alignment withone of the grooves and disposed perpendicular thereto whereby thegrooves are eccentric and rotated so that that are not in perpendicularalignment with the threaded set screw bore;

[0025]FIG. 9b is a isometric side view of the embodiment of the integralone piece coupling member shown in FIG. 9a, showing the bores formedwithin the smaller portion and larger portion shown in phantom linestogether with an external axial groove offset with respect to thethreaded set screw socket;

[0026]FIG. 10a is a frontal view of an alternate embodiment of acoupling member showing the smaller portion comprising a frustoconicalfront portion abutting a rear portion with a bore therethrough tocooperatively engage a screw;

[0027]FIG. 10b is a side view of the embodiment of FIG. 10a;

[0028]FIG. 10c is an isometric view of the embodiments of the couplingmember shown in FIGS. 10a and 10 b showing the throughbore forcooperatively engaging a screw in phantom lines;

[0029]FIG. 11a is a frontal view of an alternate embodiment of a threepiece coupling member showing the smaller portion comprising afrustoconical front portion abutting a rear portion of approximatelyequal size with a bore therethrough to cooperatively engage a screw,wherein a washer comprising a polymeric material extends coaxiallyaround the rear portion and a band extends coaxially around the washerforming the larger portion of the coupling member with a threaded setscrew socket disposed through the band, washer, and front portion of thecoupling member and the end of the frustoconical portion is castilatedforming slots and projections therearound;

[0030]FIG. 11b is an isometric view of the embodiment of the couplingmember shown in FIGS. 11a showing the throughbore for cooperativelyengaging a screw in phantom lines;

[0031]FIG. 12a is a frontal end view showing a coupling member having akeeper comprising a top spline;

[0032]FIG. 12b shows an isometric view of the embodiment of the couplingmember wherein the front end portion is approximately the same size asthe rear end portion and the rear end portion includes a keepercomprising a spline therein; and

[0033]FIG. 13 is an isometric view of the embodiment of FIG. 12Bincluding the front truncated portion includes a castilated end.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] With reference to the drawings, illustrated in FIG. 1 is anvehicle bucket type seat 10 having a seat portion 11 and a back portion12 that can be moved to various different reclined positions by liftingthe free end of a handle 40 to release a locking device on a seat tiltmechanism 20. The handle 40 on the side of the seat attaches to a lockrelease shaft that is spring biased to a seat back locking position.

[0035] The seat recliner mechanism 20 for the seat of FIG. 1 is shown inFIG. 2 and includes a shaft 21 that projects into a recess, i.e. asocket, in the handle 40 and suitable means such a screw or snap fitconnection anchors the handle to the shaft to rotate the same. Rotatingthe shaft 21 against the force of the spring bias releases the tilt lockmechanism. An end portion of the shaft 21, having a slot or holetherein, is prone to breaking off leaving a short stub shaft projectingfrom the side of the mechanism. The stub shaft that remains, (shown inFIG. 2), is that much shorter than the original as to make it impossibleto connect the handle directly thereto in an operative manner asintended by the manufacturer. In the past when this failure has occurredthe practice has been to remove the tilt mechanism and replace it with anew one and then attach a new handle thereto. Replacement time is about2 hours by someone trained to do so and thus replacement is a costlyproposition.

[0036] In accordance with the present invention, a coupling member 30 isprovided for connecting the handle 40 to the remaining stub shaft 21thereby eliminating the need to replace the entire tilt mechanism 20when the shaft breaks. The coupling 30 is a short shaft defining a largefirst portion and a smaller second portion with respective first andsecond contiguous portions 31 and 32 that have different outerdimensions, in a direction transverse to the length of the shaft,resulting in a shoulder 33. A socket 34 extends inwardly from the outerfree end of the larger diameter portion 31 to receive therein theportion of the shaft 21 that projects from the side of the tiltmechanism. A threaded set screw 35 includes a recess in the end thereofto receive an Allen wrench or the equivalent. The threaded set screw 35projects into the socket 34 to detachably anchor the coupling to theshaft. The set screw 35 is threaded through a wall of the coupling andis located closely adjacent the free outer end of the coupling. Thesmaller end portion 32 of the coupling member has a shaft diameter andprofile to project into a socket 41 in a conventional replacementhandle. In practice and by way of example the shaft end portion 31 hasan outer diameters of 0.78 of an inch and the recess in the end thereofhas a diameter of 0.50 inches. The smaller end portion 32 has an outerdiameter of 0.40 inches. The length of the coupling member is 1.11inches with the larger end being 0.60 inches in length and the depth ofthe socket therein 0.42 inches.

[0037] In the embodiment illustrated in the drawings, the couplingportion 32 has a pair of oppositely located grooves 37 had 38 disposedparallel to the axis of the coupling member for receivingcorrespondingly located ribs in the socket 41 in the handle 40 and theseprevent the handle from rotating on the shaft. There is a groove 39 onthis same coupling portion and which is disposed transverse to the axisof the coupling member. A spring clip in the socket 41 of the handle 40in a known manner snap fits into this groove to thereby retain thehandle on the coupling member. Alternatively, the coupling portion 32maybe externally threaded to mate with corresponding internal threads inthe socket 41 of the handle.

[0038] The foregoing makes a simple, inexpensive and essentiallyunnoticeable repair eliminating the need to replace the entire tiltmechanism.

[0039] In the foregoing the coupling member is described as being usedto repair a tilt mechanism having a broken shaft. It is also intendedthat an entire original equipment seat tilt mechanisms be initiallyprovided with a coupling member as described in the forgoing to connectthe handle to the lock release shaft. In this case, the shaft initiallycan be shorter in length than is presently the case and as in thepresent case the set screw 35 is positioned closely adjacent the freeouter end of the coupling member so that it bites into the portion ofthe lock release shaft that has no weakening slots or holes therein.

[0040] As best shown in FIGS. 8a-8 f, the coupling member is an integralone piece coupling member showing the optional use of internal keepercomprising at least one axial spline 50 in the larger portion of thecoupling 38 and an axial exterior groove extending along the surface ofthe smaller portion abutting the larger portion whereby a threaded setscrew socket or bore is disposed in alignment with one of the splinesand the groove and disposed perpendicular thereto. The bores are shownwithin the smaller portion and larger rear portion which includes akeeper comprising an optional interior spline and threaded set screwsocket, whereby the smaller front portion includes an external groove.As shown in FIG. 8e, an internal spline in the larger portion 31 and thegroove 37 in the smaller portion 32 are in alignment with the threadedscrew socket. The external groove within the smaller portion may abutthe larger portion with the threaded set screw socket in alignment withthe external groove and opposite one of the internal splines comprisingthe keeper. The axial groove may be used on the smaller portion withoutthe keeper or the threaded set screw socket. A smaller portion of thecoupling member having an axial exterior groove can also be aligned witha threaded set screw socket on the larger portion and a keeperconsisting of a spline disposed in the larger portion opposite thethreaded set screw socket. A smaller portion having an axial exteriorgroove aligned opposite a threaded set screw socket on the largerportion can be utilized with a keeper consisting of a spline may bedisposed in the larger portion intersecting the threaded set screwsocket.

[0041]FIGS. 9a-9 b are alternate embodiments of a integral one piececoupling member showing the use of internal keeper comprising offsetopposing grooves in the smaller portion of the coupling extending alongthe surface abutting the larger portion whereby a threaded set screwsocket is disposed in offset alignment with one of the splines and thegroove and disposed perpendicular thereto whereby the splines areeccentric and rotated so that that are not in perpendicular alignmentwith the threaded set screw bore.

[0042]FIGS. 10a-10 c are alternate embodiments of a coupling membershowing the smaller portion comprising a frustoconical rear portion 56abutting a front portion of approximately equal size with a boretherethrough to cooperatively engage a screw, wherein a washercomprising a polymeric material extends coaxially around the frontportion and a band extends coaxially around the washer forming thelarger portion of the coupling member with a threaded set screw socketdisposed through the band, washer, and front portion of the couplingmember.

[0043]FIGS. 11a-11 b are alternate embodiments of a three piece couplingmember showing the smaller portion comprising a frustoconical rearportion 56 abutting a front portion of approximately equal size with abore therethrough to cooperatively engage a screw, wherein a washer 58comprising a polymeric material extends coaxially around the frontportion and a band 60 extends coaxially around the washer forming thelarger portion of the coupling member with a threaded set screw socketdisposed through the band, washer, and front portion of the couplingmember and the castilated end 62 of the frustoconical portion formingslots and projections therearound.

[0044]FIGS. 12a-12 b are embodiments of a coupling member having akeeper comprising a top spline 64 wherein the front end portion 66 isapproximately the same size as the rear end portion 68 and the rear endportion includes a keeper comprising a spline 64 therein.

[0045]FIG. 13 is an isometric view of the embodiment of FIG. 12Bincluding a rear truncated portion 56 having a castilated end 62.

[0046] The foregoing detailed description is given primarily forclearness of understanding and no unnecessary limitations are to beunderstood therefrom, for modifications will become obvious to thoseskilled in the art based upon more recent disclosures and may be madewithout departing from the spirit of the invention and scope of theappended claims.

I claim:
 1. For use on an vehicle tilt seat a coupling member forconnecting the handle to a lock release actuating shaft of the tilt seatmechanism, said coupling member comprising a relatively short shafthaving contiguous first and second portions with outer dimensions,transverse to the length of the shaft, that differ from one another, thelarger one of said first and second portions having an unobstructedrecess extending a selected distance inwardly from a free outer end ofsuch portion in a direction toward the smaller one of said twocontiguous portions, set screw means threaded through an outer wall ofsaid coupling and projecting into said recess for detachably mountingand securely anchoring said coupling on and to said lock releaseactuating shaft for rotating the same, said smaller one of saidcontiguous portions being suitably profiled to project into a socket ina conventional handle for the tilt mechanism and cooperate with means insaid socket in said handle preventing relative movement of the handleand coupling member when the handle is moved in a direction to rotatesaid lock release actuating shaft.
 2. A method of reconnecting a handleto the lock release shaft of a seat back tilt mechanism on an vehicleseat and wherein such shaft has an outer free end portion that hasbroken away and thereby preventing reconnecting the handle directly tothe shaft, said method comprising: (a) providing a coupling member asdefined in claim 1; (b interposing said coupling member between saidshaft and said handle with the smaller one of said first and secondcontiguous portions projecting into the recess provided in said handleand the remaining portion of the lock release shaft projecting into saidrecess in the other one of said first and second portions; and (c)securely anchoring said coupling member to each of said tilt lockrelease shaft and said handle.
 3. In an vehicle seat recliner mechanismhaving a recline lock release shaft actuated conventionally by a handleattached directly to such shaft the improvement comprising providing acoupling member having a first and second contiguous portions with onesuch portion being larger than the other in a direction transverse tothe length of the coupling and detachably connecting said first andsecond portions respectively to said shaft and said handle.